US9687773B2 - Fuel deoxygenation and fuel tank inerting system and method - Google Patents
Fuel deoxygenation and fuel tank inerting system and method Download PDFInfo
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 - US9687773B2 US9687773B2 US14/310,531 US201414310531A US9687773B2 US 9687773 B2 US9687773 B2 US 9687773B2 US 201414310531 A US201414310531 A US 201414310531A US 9687773 B2 US9687773 B2 US 9687773B2
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- B—PERFORMING OPERATIONS; TRANSPORTING
 - B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
 - B01D—SEPARATION
 - B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
 - B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
 - B01D53/04—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
 - B01D53/047—Pressure swing adsorption
 
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- B—PERFORMING OPERATIONS; TRANSPORTING
 - B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
 - B01D—SEPARATION
 - B01D19/00—Degasification of liquids
 - B01D19/0005—Degasification of liquids with one or more auxiliary substances
 
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- B—PERFORMING OPERATIONS; TRANSPORTING
 - B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
 - B01D—SEPARATION
 - B01D19/00—Degasification of liquids
 - B01D19/0021—Degasification of liquids by bringing the liquid in a thin layer
 - B01D19/0026—Degasification of liquids by bringing the liquid in a thin layer in rotating vessels or in vessels containing movable parts
 
 - 
        
- B—PERFORMING OPERATIONS; TRANSPORTING
 - B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
 - B01D—SEPARATION
 - B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
 - B01D53/22—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by diffusion
 - B01D53/225—Multiple stage diffusion
 
 - 
        
- B—PERFORMING OPERATIONS; TRANSPORTING
 - B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
 - B01D—SEPARATION
 - B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
 - B01D53/22—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by diffusion
 - B01D2053/221—Devices
 
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- B—PERFORMING OPERATIONS; TRANSPORTING
 - B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
 - B01D—SEPARATION
 - B01D2256/00—Main component in the product gas stream after treatment
 - B01D2256/10—Nitrogen
 
 - 
        
- B—PERFORMING OPERATIONS; TRANSPORTING
 - B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
 - B01D—SEPARATION
 - B01D2257/00—Components to be removed
 - B01D2257/10—Single element gases other than halogens
 - B01D2257/104—Oxygen
 
 - 
        
- B—PERFORMING OPERATIONS; TRANSPORTING
 - B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
 - B01D—SEPARATION
 - B01D2257/00—Components to be removed
 - B01D2257/70—Organic compounds not provided for in groups B01D2257/00 - B01D2257/602
 - B01D2257/702—Hydrocarbons
 
 - 
        
- B—PERFORMING OPERATIONS; TRANSPORTING
 - B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
 - B01D—SEPARATION
 - B01D2258/00—Sources of waste gases
 - B01D2258/06—Polluted air
 
 - 
        
- B—PERFORMING OPERATIONS; TRANSPORTING
 - B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
 - B01D—SEPARATION
 - B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
 - B01D53/22—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by diffusion
 - B01D53/229—Integrated processes (Diffusion and at least one other process, e.g. adsorption, absorption)
 
 - 
        
- B—PERFORMING OPERATIONS; TRANSPORTING
 - B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
 - B01D—SEPARATION
 - B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
 - B01D53/34—Chemical or biological purification of waste gases
 - B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
 - B01D53/86—Catalytic processes
 - B01D53/864—Removing carbon monoxide or hydrocarbons
 
 
Definitions
- the present invention generally relates to fuel deoxygenation, and more particularly relates to systems and methods for deoxygenating fuel and, in some embodiments, inerting fuel tanks.
 - Modern aircraft rely on efficient heat sink options for thermal management.
 - the jet fuel that is supplied to the propulsion engines is often a convenient sink for excess thermal energy, and the energy is efficiently retained in the engine thermodynamic cycle.
 - the presence of molecular oxygen or entrained air limits the ability of fuel to absorb heat beyond approximately 300° F. without undergoing deleterious thermal degradation.
 - Thermal degradation often appears as solid materials which adhere to surfaces and degrades fuel system performance increase.
 - wetted surfaces comprised of metallic materials can further catalyze the reaction of oxygen with fuel and subsequent formation of carbonaceous, coke-like material.
 - an aircraft fuel deoxygenation and tank inerting system includes an inert gas source, a fuel deoxygenation system, and an air/fuel heat exchanger.
 - the inert gas source is configured to supply inert gas having an oxygen concentration of less than 3%.
 - the fuel deoxygenation system is adapted to receive fuel from a fuel source and the inert gas from the inert gas source.
 - the fuel deoxygenation system is configured to remove oxygen from the fuel and thereby generate and supply deoxygenated fuel and oxygen-rich purge gas.
 - the air/fuel heat exchanger is adapted to receive compressed air from a compressed air source and the deoxygenated fuel from the fuel deoxygenation system.
 - the air/fuel heat exchanger is configured to transfer heat from the compressed air to the deoxygenated fuel, to thereby supply cooled compressed air and heated deoxygenated fuel.
 - a fuel deoxygenation system in another embodiment, includes a housing and a disk.
 - the housing has a fuel inlet, a fuel outlet, a gas inlet, and a gas outlet.
 - the fuel inlet is adapted to receive fuel from a fuel source
 - the gas inlet is adapted to receive inert gas from an inert gas source.
 - the disk is rotationally mounted in the housing and is coupled to receive a drive torque. The disk is configured, upon receipt of the drive torque, to rotate and thereby produce a thin film of fuel thereon and propel fuel radially outward toward an outer perimeter of the disk.
 - FIGS. 1-3 depict simplified schematic representations of embodiments of integrated deoxygenation and fuel inerting systems
 - FIGS. 4-6 depict various embodiments of inert gas sources that may be used to implement the systems of FIGS. 1-3 ;
 - FIGS. 7-14 depict various embodiments of fuel deoxygenation systems that may be used to implement the systems of FIGS. 1-3 .
 - FIGS. 1-3 embodiments of an integrated deoxygenation and fuel inerting system 100 is depicted.
 - Each of the depicted systems 100 includes an air/fuel heat exchanger 102 and a fuel deoxygenation system 104 .
 - the air/fuel heat exchanger 102 is coupled to receive compressed air from a compressed air source 106 , and deoxygenated fuel from the fuel deoxygenation system 104 .
 - heat is transferred from the compressed air to the deoxygenated fuel to thereby supply relatively cool compressed air and relatively hot deoxygenated fuel.
 - the relatively cool compressed air is supplied to a load 108 , such as an air cycle machine or environmental control system, and the relatively hot deoxygenated fuel is supplied to a gas turbine engine 112 .
 - the fuel deoxygenation system 104 is coupled to receive fuel from a fuel source 114 , and an inert gas, such as nitrogen (N 2 ), from an inert gas source 116 .
 - the fuel deoxygenation system 104 is configured to remove oxygen from the fuel and, as described above, supply the deoxygenated fuel to the air/fuel heat exchanger 102 .
 - the embodiments of the fuel deoxygenation system 104 that are described in more detail further below will reduce dissolved oxygen in the fuel from about 70 ppm to less than 10 ppm and, in some instance, less than 1 ppm.
 - the inert gas source 116 may be a stand-alone source of inert gas or, as depicted in FIGS. 2 and 3 , it may be the on-board fuel tank inerting system 202 .
 - the fuel tank inerting system 202 may be variously configured and implemented.
 - relatively high pressure air such as a portion of the relatively cool compressed air, is fed to a fuel tank inerting membrane 402 (see FIG. 4 ).
 - a typical fuel tank inerting membrane is comprised of a large number of hollow tubes that have preferential permeance for oxygen over nitrogen. Thus, as the compressed air flows through the hollow tubes, nitrogen-rich gas and oxygen-rich gas are produced.
 - the oxygen-rich gas is vented to a lower pressure environment, such as overboard or to the aircraft cabin.
 - a major portion of the nitrogen-rich gas is supplied to the fuel tank ullage, and another portion is supplied to a secondary purification system 204 .
 - the fuel tank inerting system 202 may alternatively be configured as a pressure-swing adsorption system, a catalytic inert gas generation system, stored inert gas in a cylinder, cryogenic inert gas, or any one of numerous other supplies of low-oxygen inert gas.
 - the nitrogen-rich gas that the fuel tank inerting system 202 supplies typically has an oxygen concentration of about 10-12%, which is sufficient to inert the fuel tank(s). However, it is preferable the fuel deoxygenation system 104 be supplied with nitrogen-rich gas having an oxygen concentration below 1%, and most preferably below 0.5%. Although the size of, and flow through, the fuel tank inerting membrane could be adjusted to yield a gas with less than 1% oxygen, in preferred embodiments the secondary purification system 204 is used. The secondary purification system 204 further reduces the concentration of oxygen from approximately 10-12% to less than 1%, and most preferably less than 0.5%. The lower concentration of oxygen generated by the secondary purification system 204 allows a greater reduction of oxygen from the fuel and therefore better fuel thermal stability.
 - the secondary purification system 204 may be implemented using any one of numerous known technologies. For example, it may be configured as a pressure-swing adsorption system, a catalytic oxidation system, or a chemical reactant such as an activated metal. In one embodiment, which is depicted in FIG. 4 , the secondary purification system 204 is configured as a second inerting membrane 404 .
 - the second inerting membrane 404 is configured similar to the fuel tank inerting membrane 402 , and thus produces nitrogen-rich gas and oxygen-rich gas. A portion of the nitrogen-rich gas discharged from the fuel tank inerting membrane 402 is supplied to the second inerting membrane 404 .
 - the flow requirement for the second inerting membrane 404 is much less than the flow requirement for the fuel tank inerting membrane 402 .
 - the second inerting membrane 404 provides a second separation step, which supplies much higher concentration nitrogen and much lower concentration oxygen to fuel deoxygenation system 104 .
 - the nitrogen-rich gas discharged from the fuel tank inerting membrane 402 is at a relatively high pressure. As such, there is sufficient pressure to induce permeation of oxygen through the second inerting membrane 404 .
 - a non-illustrated boost pump may be used to pressurize the nitrogen-rich gas to achieve better performance in the second membrane.
 - the oxygen-rich gas from the second inerting membrane 404 may be combined with that from the fuel inerting membrane 402 and supplied to the fuel tank (s), or it may be vented.
 - the inert gas source 116 could be a stand-alone source, and that one or both of the fuel tank inerting system 202 and secondary purification system 204 could be variously implemented.
 - the inert gas source 116 is implemented as a pressure-swing adsorption (PSA) generator 502 .
 - the PSA generator 502 is configured as a twin-tower adsorbent that separates oxygen and nitrogen from the relatively high pressure air.
 - the nitrogen from the PSA generator 502 is supplied to the fuel deoxygenation system 104 .
 - One advantage of this embodiment is the relatively high separation of nitrogen possible in a small PSA generator. It will be appreciated that the PSA generator 502 may be used by itself or in combination with one or more other systems to provide very high purity nitrogen and therefore very low concentrations of residual oxygen in the deoxygenated fuel.
 - the inert gas source 116 is implemented using a catalytic reactor 602 to oxidize fuel vapor and thereby deplete oxygen.
 - a catalyst can be used to promote this reaction at relatively low temperature.
 - a first heat exchanger 604 is used to raise the temperature of the air and fuel vapor mixture to the point where it can catalytically oxidize.
 - a second heat exchanger 606 is used decrease the temperature to a level that is safe for venting in an open system or for recycling to the fuel tank in a closed loop system.
 - a small amount of gas which is comprised of carbon dioxide, highly concentrated nitrogen, and trace inert gas (e.g., argon), is diverted to the fuel deoxygenation system 104 .
 - trace inert gas e.g., argon
 - the catalytic combustion process also generates water, which is removed by a non-illustrated water separator before use.
 - the inert gas source 116 may be implemented as a multi-stage device in which the first stage comprises a membrane, and the second stage comprises one of a pressure-swing adsorption (PSA) generator, a membrane, or a catalytic reactor.
 - the first stage comprises a catalytic reactor
 - the second stage comprises one of a membrane, a pressure-swing adsorption (PSA) generator, or a catalytic reactor.
 - the relatively hot fuel may be supplied to a second heat exchanger 302 before being supplied to the engine.
 - cooling air is supplied to the second heat exchanger 302 to thereby supply cooled-cooling air.
 - This embodiment reduces the amount of bleed air used to cool engine equipment.
 - the embodiments depicted in FIGS. 1-3 may also include a heat exchanger for the fuel deoxygenation system 104 . It is typically most desirable to add heat downstream of the fuel deoxygenation system 104 . However, the embodiments disclosed herein also allow some heat to be added upstream of the fuel deoxygenation system 104 to increase the rate at which deoxygenation will occur and to accomplish more extensive deoxygenation due to the lower oxygen solubility in fuel at higher temperatures.
 - the depicted deoxygenation system 104 includes an integrated contactor and separator 702 , referred to herein as a contactor-separator assembly (CSA).
 - the CSA 702 may be implemented using one stage or a plurality of stages.
 - the CSA is implemented using three stages 704 ( 704 - 1 , 704 - 2 , 704 - 3 ). Regardless of the number of stages, each stage 704 preferably includes one or more disks 706 , a fuel inlet 708 , a fuel outlet 710 , a gas inlet 712 , and a gas outlet 714 .
 - the disks 706 are preferably mounted on a common shaft 716 , and the stages 704 are separated by a mechanical barrier (or housing) 718 .
 - the shaft 716 is coupled to a torque source 720 that supplies a drive torque to the shaft 716 , thereby rotating the shaft 716 and the disks 706 .
 - FIGS. 8 and 9 are simplified end and side views, respectively, of one stage 704 .
 - fuel is injected into a stage 704 in a direction that is preferably perpendicular to the spinning disk 706 .
 - the fuel is supplied into the stage 704 via the fuel inlet 708 .
 - the fuel inlet includes a nozzle 902 that is configured to produce an aerosol. As the fuel impinges on the rotating disk 706 , a thin film of fuel is produced.
 - the inert gas is supplied to the stage 704 via the inert gas inlet 712 .
 - the inert gas contacts the thin film of fuel distributed on the spinning disk 706 , it equilibrates with the dissolved oxygen in the fuel.
 - the difference in oxygen concentration in the fuel and the inert gas causes dissolved oxygen in the fuel to be transferred to the inert gas, creating a purge gas that is expelled via the gas outlet 714 .
 - a flow of fresh inert gas is maintained to remove the purge gas.
 - the inert gas preferably flows counter-current to the fuel flow.
 - the gas outlet from the last stage e.g., 704 - 3
 - flows into the stage just upstream e.g., 704 - 2 ).
 - the gas and fuel flow in opposite direction across stages.
 - a fuel collection manifold 806 is disposed adjacent to the outer perimeter 804 and collects the deoxygenated fuel.
 - the fuel collection manifold 806 may be coupled to receive the deoxygenated fuel via a simple port, a centrifugal weir, or other suitable extraction device.
 - the configuration described above may be implemented with multiple parallel disks 706 to increase throughput or may use a series flow liquid configuration where an upstream stage 104 uses the dynamic fuel pressure to feed liquid fuel to a second stage.
 - the CSA may also employ vanes near the nozzle 902 to more efficiently establish a rotating flow pattern than is possible via simple contact with the rotating disk 706 .
 - FIG. 10 Another embodiment of a fuel deoxygenation system 104 is depicted in FIG. 10 , and will now be described.
 - This system 104 includes a separate contactor 1002 and separator 1004 .
 - the inert gas and fuel are supplied to the contactor 1002 at a precisely controlled pressure for optimal deoxygenation condition.
 - the system 104 includes two pressure control valves—a fuel pressure control valve 1006 and a gas pressure control valve 1008 .
 - this system 104 may, in some embodiments, also include a fuel back pressure control valve 1012 and a purge gas back pressure control valve 1014 to provide additional pressure control.
 - the contactor 1002 may be implemented using any one of numerous contactors known in the art.
 - the contactor 1002 may employ a series of mechanical plates, distributed packing material, or such other mechanical surfaces to provide intimate contact between vapor and liquid phases. As the admixture of fuel and inert gas is processed through the low pressure region of the contactor 1002 , and equilibrium consistent with Henry's law is established between the two phases, the outflow from the contactor 1002 is directed to the separator 1004 .
 - the separator 1004 may be implemented using any one of numerous known separators. For example, it may be a simple gravity-based vessel within which the inert gas phase distributes to the upper portion while the liquid fuel phase distributes to the lower volume within the container. To provide increased efficiency, the separator 1004 can be implemented using a centrifugal separator and, as an option, by using pressure gradients such as a vacuum. A centrifugal separator provides the advantages of effective gas bubble removal from the fuel and thus preventing issues such as cavitation in downstream pumps.
 - the combined fuel/gas phase is supplied to the separator 104 , and centrifugal force moves the fuel to the outside part of separator 104 where it is discharged into a DEOX fuel line 1006 .
 - the lower density phase which includes the inert gas and oxygen from the fuel, is recirculated through inert gas purification system and reintroduced into the contactor, or purged from the system.
 - the separator 1004 may also be optimized to incorporate an optimized quantity of dissolved or entrained gas in the fuel to provide suitable compressibility for the fuel pumps.
 - thermodynamic stage is defined as the equilibrium separation of dissolved oxygen from the fuel at one specific condition of temperature and pressure in a vessel.
 - the depicted embodiment includes two stages—a first stage 1102 - 1 and a second stage 1102 - 2 .
 - the first and second stages 1102 each include a contactor 1104 ( 1104 - 1 , 1104 - 1 ) and a separator 1106 ( 1106 - 1 , 1106 - 2 ).
 - the stages 1102 are cascaded to provide a greater degree of oxygen separation from the fuel than is possible using a one stage system.
 - Fuel is supplied to the first contactor 1104 - 1 where it is contacted with the vapor phase that has already been used to remove oxygen from the fuel in the second stage 1102 - 2 .
 - the mixed phase from the first contactor 1104 - 1 is supplied to the first separator 1106 - 1 .
 - the deoxygenated fuel from the first separator 1106 - 1 is supplied to the second contactor 1104 - 2 where fresh inert gas from the inert gas supply 116 is contacted with the deoxygenated fuel from the first stage 1102 - 1 .
 - the inert gas discharged from the second separator 1106 - 2 is returned to the first stage 1102 - 1 , and more particularly to the first contactor 1104 - 1 .
 - This counter-flow system provides a higher level of deoxygenation than possible with the single stage system shown in FIG. 10 .
 - FIG. 12 Yet another embodiment, which is depicted in FIG. 12 , is similar to the one depicted in FIG. 10 , except that the contactor 1202 is based on direct contact. More specifically, fuel is supplied to a nozzle 1204 that is configured to generate small droplets or an aerosol of fuel. The droplets or aerosol of fuel exchange oxygen with the inert gas, and the admixture is supplied to the separator 1206 , which may be implemented using any one of the above-described separators. This particular deoxygenation system 104 may be lower in weight and smaller in size due to the relatively fast gas exchange enabled by the small fuel droplets.
 - this embodiment depicts a fuel deoxygenation system 104 in which a pump 1302 supplies a fraction of the inert gas is recirculated back to the contactor 1002 to increase the amount of gas contacting the liquid fuel without needing to generate additional inert gas.
 - An accumulator 1304 may optionally be used to control system stability.
 - the recirculated inert gas may be directed upstream (see the dotted line in FIG. 13 ) or downstream of the inert gas supply.
 - the recirculated gas may be input at any stage 704 .
 - the recirculation gas supplied to the first or second stage leaving the most pure inert gas to contact the final liquid stage, which would combine the benefits of higher recirculation on transfer rate while maintaining the advantage of counter-flow on the final fuel DEOX quality.
 - the systems and a methods described herein remove dissolved and entrained air from fuel.
 - the systems include a contactor and separator combined with an inert gas supply to remove oxygen.
 - Oxygen removal enables additional heat to be input to the fuel before deposits start to form, which improves aircraft specific fuel consumption (SFC), potentially by 0.5 to 2%.
 - SFC aircraft specific fuel consumption
 - Henry's law which is very well understood, a practical approach has not been applied to remove dissolved oxygen from aircraft fuel systems.
 - the systems described herein may be located in various parts of an aircraft, and thus operate at various temperatures, and be integrated with multiple subsystems.
 
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Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title | 
|---|---|---|---|
| US14/310,531 US9687773B2 (en) | 2014-04-30 | 2014-06-20 | Fuel deoxygenation and fuel tank inerting system and method | 
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| Application Number | Priority Date | Filing Date | Title | 
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| US201461986464P | 2014-04-30 | 2014-04-30 | |
| US14/310,531 US9687773B2 (en) | 2014-04-30 | 2014-06-20 | Fuel deoxygenation and fuel tank inerting system and method | 
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| US20150314229A1 US20150314229A1 (en) | 2015-11-05 | 
| US9687773B2 true US9687773B2 (en) | 2017-06-27 | 
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